Joist table systems and methods

ABSTRACT

A joist assembly system that is structured for dynamic retrieval of components, dynamic and precise positioning and location of retrieved components, assembly of the components to form a joist, and delivery of the assembled joist. The joist assembly system has a plurality of material handling systems, a plurality of welding systems, and a rigging table system. The material handling systems are structured to load and position the components such as chords and webs onto the rigging table. The rigging table in turn supports the chords or webs. Subsequently, the plurality of welding systems weld the webs to the chords to form the joist.

CROSS REFERENCE AND PRIORITY CLAIM UNDER 35 U. S.C. §119

This application claims priority to U.S. Provisional Application No.63/190,458 entitled “Joist Table Systems and Methods” filed on May 19,2021, which is assigned to the assignee hereof and the entirety of whichis incorporated by reference herein.

FIELD

The present disclosure relates generally to joist assembly systems andmethods of forming joists using the joist systems. More specifically, ajoist system with robots that deliver joists members to a table and weldthe joist members together to form the joists.

BACKGROUND

Tables used to assemble structures such as trusses and joists havetypically incorporated jigs or supports that hold the chord members andweb members together in the desired configuration, which allows a workerto weld the chord members and web members together in the desiredconfiguration. Typically, the members may be delivered to or near thetable through the use of a machine, such as through a forklift, conveyorbelt, rollers, or the like.

SUMMARY OF THE EMBODIMENTS OF THE INVENTION

The present invention relates generally to a joist assembly system thatis structured for dynamic retrieval of components, dynamic and precisepositioning and location of retrieved components, assembly of thecomponents to form a joist, and delivery of the assembled joist.Specifically, the joist assembly system comprises a plurality ofmaterial handling systems, a plurality of welding systems, and a riggingtable system. Typically, the material handling systems are structured toload and position the components such as chords and webs onto therigging table system. The rigging table system in turn supports thechords or webs. Subsequently, the plurality of welding systems may weldthe webs to the chords to form the joist.

One embodiment of the invention is a joist assembly system comprising: aplurality of material handling systems; a plurality of welding systems;and a rigging table system, wherein the material handling systems loadchords and webs to the rigging table, the rigging table supports thechords and webs, and the plurality of welding systems weld the webs tothe chords.

In further accord with an embodiment of the invention, the joistassembly system further comprises: a support structure having a firstlevel and a second level located at least partially above the firstlevel; wherein the plurality of welding systems are located on the firstlevel; and wherein the plurality of material handling systems arelocated on the second level.

In yet another embodiment of the invention, the joist assembly systemfurther comprises: a support structure having a first level and a secondlevel located at least partially above the first level; wherein theplurality of material handling systems are located on the first level;and wherein the plurality of welding systems are located on the secondlevel.

In further accord with an embodiment of the invention, the plurality ofmaterial handling systems are configured to pick chord portions or webs.

In another embodiment of the invention, the plurality of materialhandling systems comprise: a plurality of chord material handlingsystems; and a plurality of web material handling systems.

In yet another embodiment of the invention, the plurality of weldingsystems comprise: a plurality of first welding systems adjacent a firstside of the rigging table system; and a plurality of second weldingsystems adjacent a second side of the rigging table system.

In further accord with an embodiment of the invention, the rigging tablecomprises: a plurality of upper chord projections spaced apart to form aplurality of upper chord cavities, wherein the plurality of upper chordcavities hold a first upper chord portion of the chords; and a pluralityof lower chord projections spaced apart to from a plurality of lowerchord cavities, wherein the plurality of lower chord cavities hold afirst lower chord portion of the chords; wherein the plurality of upperchord projections or the plurality of lower chord projections allow thefirst upper chord portion to be spaced different distances from thefirst lower chord portion.

In another embodiment of the invention, the plurality of materialhandling systems are structured to hold the webs in place while thewelding systems at least partially weld the webs.

In yet another embodiment of the invention, the rigging table comprisesweb jigs that are structured to hold the webs in place.

In still another embodiment of the invention, the rigging table isstructured to support a first upper chord and a first lower chord of thechords, and webs; wherein the rigging table is structured to support asecond upper chord and a second lower chord of the chords positionedover the first upper chord and the first lower chord.

In still another embodiment of the invention, the joist assembly systemfurther comprises a material supply station, wherein the material supplystation provides the chords and the webs to a picking location for theplurality of material handling systems.

In still another embodiment of the invention, the rigging table systemfurther comprises a discharging system configured to remove an assembledjoist from the rigging table.

In still another embodiment of the invention, the discharging systemfurther comprises a plurality of rollers, wherein the plurality ofrollers are configured to extend from the rigging table and retractwithin the rigging table, wherein the plurality of rollers rotate, andwherein when the plurality of rollers are extended a joist is disengagedfrom rigging table and rotating rollers move the joist off of therigging table.

Another embodiment of the invention is a method for assembling a joist,the method comprising: providing a plurality of upper chords, aplurality of lower chords and a plurality of web members at a materialsupply station; retrieving, via a plurality of chord material handlingsystems of a plurality of material handling systems, a first upper chordof the plurality of upper chords and a first lower chord of theplurality of lower chords from the material supply station; positioning,via the plurality of chord material handling systems, the first upperchord and the first lower chord at a rigging table system; retrieving,via a plurality of web material handling systems of the plurality ofmaterial handling systems, a first plurality of web members of theplurality of web members from the material supply station; positioning,via the plurality of web material handling systems, the first pluralityof web members at the rigging table system; joining, via a plurality ofwelding systems, the first upper chord, the first lower chord, and thefirst plurality of web members; retrieving, via the plurality of webmaterial handling systems, a second plurality of web members from thematerial supply station; positioning, via the plurality of web materialhandling systems, the second plurality of web members at the riggingtable system; joining, via the plurality of welding systems, the firstupper chord, the first lower chord, the first plurality of web members,and the second plurality of web members; retrieving, via the pluralityof chord material handling systems, a second upper chord of theplurality of upper chords and a second lower chord of the plurality oflower chords from the material supply station; positioning, via theplurality of chord material handling systems, the second upper chord andthe second lower chord at a rigging table system; joining, via theplurality of welding systems, the first upper chord, the first lowerchord, the second upper chord, the second lower chord, the firstplurality of web members, and the second plurality of web members toform a joist; and discharging, via a discharging system, the joist fromthe rigging table system.

To the accomplishment the foregoing and the related ends, the one ormore embodiments of the invention comprise the features hereinafterfully described and particularly pointed out in the claims. Thefollowing description and the annexed drawings set forth certainillustrative features of the one or more embodiments. These features areindicative, however, of but a few of the various ways in which theprinciples of various embodiments may be employed, and this descriptionis intended to include all such embodiments and their equivalents.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying drawings illustrate embodiments of the presentdisclosure, in which:

FIG. 1 is a front perspective view of the joist assembly system, inaccordance with embodiments of the invention.

FIG. 2A is a front perspective view of a of the joist assembly systemwith some of the surrounding structure removed, in accordance withembodiments of the invention.

FIG. 2B is a top view of the joist assembly system of FIG. 2A.

FIG. 2C is a rear perspective view of the joist assembly system of FIG.2A.

FIG. 2D is a detail view of the rigging table system of the joistassembly system of FIG. 2A.

FIG. 3A is a front perspective view of a joist assembly system depictinga retrieval process of chord components, in accordance with embodimentsof the invention.

FIG. 3B is a front perspective view the schematic representation of thejoist assembly system of FIG. 3A depicting loading process of chordcomponents.

FIG. 4 is a front perspective view of a joist assembly system depictingloading process of chord components onto a rigging table system, inaccordance with embodiments of the invention.

FIG. 5A is a detail view of the joist assembly system of FIG. 4depicting loading process of chord components onto a rigging tablesystem, in accordance with embodiments of the invention.

FIG. 5B is an enlarged detail view of the joist assembly system of FIG.5A depicting a detail view of the rigging table system, in accordancewith embodiments of the invention.

FIG. 6A is a detail view of the joist assembly system of FIG. 4depicting loading process of chord components onto a rigging tablesystem, in accordance with embodiments of the invention.

FIG. 6B is an enlarged detail view of the joist assembly system of FIG.6A depicting a detail view of the rigging table system, in accordancewith embodiments of the invention.

FIG. 7A is a front perspective view of a joist assembly system depictingloading process of chord components onto a rigging table system, inaccordance with embodiments of the invention.

FIG. 7B is an enlarged view of the joist assembly system of FIG. 7Adepicting loading process of chord components onto the rigging tablesystem, in accordance with embodiments of the invention.

FIG. 8 is a front perspective view of a joist assembly system with thematerial handling systems being retracted, in accordance withembodiments of the invention.

FIG. 9 is a front perspective view of a joist assembly system depictingretrieval process of web components, in accordance with embodiments ofthe invention.

FIG. 10 is a front perspective view of a joist assembly system depictingloading process of web components, in accordance with embodiments of theinvention.

FIG. 11A is a front perspective view of a joist assembly systemdepicting loading process of web components onto a rigging table system,in accordance with embodiments of the invention.

FIG. 11B is an enlarged view of the joist assembly system of FIG. 11Adepicting loading process of web components onto the rigging tablesystem, in accordance with embodiments of the invention.

FIG. 12A is a front perspective view of a joist assembly systemdepicting joining process of components at a rigging table system, inaccordance with embodiments of the invention.

FIG. 12B is an enlarged view of a joist assembly system of FIG. 12Adepicting joining process of components at a rigging table system, inaccordance with embodiments of the invention.

FIG. 13 is a front perspective view of a joist assembly system depictingretrieval process of additional web components, in accordance withembodiments of the invention.

FIG. 14 is a front perspective view of a joist assembly system depictingloading process of additional web components, in accordance withembodiments of the invention.

FIG. 15 is a front perspective view of a joist assembly system depictingjoining process of additional web components at a rigging table system,in accordance with embodiments of the invention.

FIG. 16 is a front perspective view of a joist assembly system depictingretrieval process of additional chord components, in accordance withembodiments of the invention.

FIG. 17 is a front perspective view of a joist assembly system depictingloading process of additional chord components, in accordance withembodiments of the invention.

FIG. 18 is a front perspective view of a joist assembly system depictingloading process of additional chord components onto a rigging tablesystem, in accordance with embodiments of the invention.

FIG. 19A is a front perspective view of a joist assembly systemdepicting joining process of additional chord components at a riggingtable system, in accordance with embodiments of the invention.

FIG. 19B is an enlarged view of a joist assembly system of FIG. 19Adepicting joining process of the additional components at the riggingtable system, in accordance with embodiments of the invention.

FIG. 19C is an enlarged view of a joist assembly system of FIG. 19Adepicting discharging process of a joist assembly from the rigging tablesystem, in accordance with embodiments of the invention.

FIG. 20 is a front perspective view of a joist assembly system depictingdischarging process of a joist assembly, in accordance with embodimentsof the invention.

FIG. 21A, is a side perspective view of a web member supply system, inaccordance with embodiments of the invention.

FIG. 21B, is a side perspective view of a web member supply system, inaccordance with embodiments of the invention.

FIG. 22 is an end perspective view of a chord member supply system, inaccordance with embodiments of the invention.

FIG. 23 is a schematic view of a network diagram, in accordance withembodiments of the invention.

FIG. 24 is a process flow illustrating the assembly process using thejoist assembly system, in accordance with embodiments of the invention

FIG. 25 illustrates one example joist that may be assembled using thejoist assembly system, in accordance with embodiments of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention will now be described more fullyhereinafter with reference to the accompanying drawings, in which some,but not all, embodiments of the invention are shown. Indeed, theinvention may be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will satisfy applicablelegal requirements. Like numbers refer to like elements throughout.

FIGS. 1-22 illustrate various views of the joist assembly system 1, inaccordance with embodiments of the invention. The joist assembly system1 of the present disclosure is structured for dynamic retrieval ofcomponents or members 200, dynamic and precise positioning and locationof retrieved components or members 200, assembly of the components toform a joist 220, and delivery of the assembled joist 220.

As described herein, the use of the term component 200 or member 200 mayrefer to one or more parts/components that may be assembled together toform a structural member such as a joist 220. One embodiment of a joistis illustrated in FIG. 25 for reference. In this regard, the componentsor members 200 may comprise one or more chords 222 and webs 238, or thelike, or portions thereof. The chords 222 may comprise one or more upperchords 224 and one or more lower chords 226 with the web members 238arranged therebetween so that the one or more upper chords 224 and oneor more lower chords 226 are spaced apart by a predetermined distance.The joist 220 may be associated with joist parameters such as a minimumjoist size, maximum joist size, minimum depth, maximum depth, maximumchord size, chord size, truss depth, web position and orientation, andweld lengths. The chords 222 and webs 238 may have any type of shape(e.g., L-shaped, U-shaped, C-shaped, round, oval, square, rectangular,non-uniform, or the like); however, in the illustrated embodiments thechords 222 are formed from two L-shaped members (e.g., back to back),while the webs 238 are formed from a single L-shaped member.

In general, as illustrated by FIGS. 1-22, the joist assembly system 1 ofthe present invention comprises a plurality of material handling systems30, a plurality of welding systems 60, and a rigging table system 10.Typically, the material handling systems 30 are structured to load andposition the components or members 200 such as chords 222 and webs 238onto the rigging table system 10. The rigging table system 10 in turnsupports the chords 222 or webs 238. Subsequently, the plurality ofwelding systems 60 may weld the webs 238 to the chords 222 to form thejoist 220. The assembled joist may then be discharged from the riggingtable and transported therefrom.

Typically, the joist assembly system 1 may comprise a support structure94 provided on a support floor 92. Typically, the support floor 92 maycomprise a first lateral side 92 a and an opposite second lateral side92b. Moreover, the support structure 94 may comprise a first level 96located proximate the support floor 92 and a second level 98 located atleast partially above the first level 96. In some embodiments, thesupport structure 94, as well as its first level 96 and second level 98may form a structural framework for supporting (e.g., holding, locating,positioning, separating, and/or otherwise accommodating) elements of thejoist assembly system 1 such as the a plurality of material handlingsystems 30, a plurality of welding systems 60, and a rigging tablesystem 10. The support structure 94 may be made from metals, alloys,composites, concrete, plastics, wood, and/or any other suitable naturalor synthetic materials. Although, the support structure 94 is describedas having two levels, it is understood that support structure 94 mayhave more or fewer levels.

The support structure 94 may comprise one or more material supplystations 40. The material supply station 40 is structured to supply(e.g., store, stock, provide, or the like) one or more components ormembers 200 (e.g., one or more chords 222 and webs 238). In this regard,the material supply station 40 may comprise one or more pallets forstoring the one or more components or members 200 (e.g., one or morechords 222 and webs 238). Typically, the material supply station 40 maybe structured such that the components or members 200 (e.g., one or morechords 222 and webs 238) stored therein may be retrieved by a pluralityof material handling systems 30 without obstructing or slowing down therespective material handling system 30 and without dislodging thepallets of the material supply station 40 and other storedcomponents/members 200, as will be described herein in further detail.The material supply station 40 may comprise a first picking location 42that is structured to store one or more chords 222 and a second pickinglocation 44 that is structured to store one or more web members 238. Asillustrated, in some embodiments, the material supply station 40 may beprovided at the second level 98. It is contemplated that in otherembodiments, the material supply station 40 may be provided elsewhere,such as at the first level 96. As will be described in further detailwith respect to FIGS. 21A-22, the material supply station 40 may furthercomprise web and/or chord supply systems 300 that are used to supply theweb members 238 and the chord members 222 to the material supply station40.

Material Handling Systems

As discussed, the joist assembly system 1 comprises a plurality ofmaterial handling systems 30. Typically, the material handling systems30 are structured to load (e.g., pick, grip, clutch, or the like)members 200 (e.g., one or more chords 222 and webs 238) stored at arespective picking location at the material supply station 40, transportthem to the rigging table system 10 and subsequently position themembers 200, such as chords 222 and webs 238, onto the rigging tablesystem 10 in a predetermined position and orientation for assembly.Moreover, the material handling system 30 may hold (e.g., maintain, orthe like) the members 200 in their correct position/orientation while aplurality of welding systems 60 join (e.g., weld, or the like) themembers 200 together, thereby precluding any undesirable displacementduring the joining process.

In some embodiments, the joist assembly system 1 is illustrated ashaving the plurality of material handling systems 30 provided at thesecond level 98. However, in other embodiments, the plurality ofmaterial handling systems 30 may be provided elsewhere, such as at thefirst level 96. Moreover, the plurality of material handling systems 30may further comprise a plurality of chord material handling systems 32that are structured for loading (e.g., picking, transporting, andpositioning) one or more chords 222, such as one or more upper chords224 and/or one or more lower chords 226. The plurality of materialhandling systems 30 may further comprise a plurality of web materialhandling systems 34 that are structured for loading (e.g., picking,transporting, and positioning) one or more web members 238. As such, insome embodiments the one or more material handling systems 30 mayconfigured to load both chords 222 and webs 238, or may be specializedthat one some material handling systems 30 load only chords 222 whileother material handling systems 30 load only webs 238.

In some embodiments, the plurality of material handling systems 30 maybe automated (e.g., controllable and/or programmable) machines, such asrobots, robotic arms, and/or the like. In this regard, the plurality ofmaterial handling systems 30 may comprise an end effector that isstructured to pick (e.g., grip, clutch, hold, position, rotate, and/orthe like) one or more respective members 200 (e.g., one or more chords222 and one or more webs 238). The plurality of material handlingsystems 30 may be chosen from a cartesian robot whose axes areassociated with a cartesian coordinate system, a cylindrical robot whoseaxes are associated with a cylindrical coordinate system, a spherical orpolar robot whose axes are associated with a polar coordinate system, anarticulated robot such as a 6 axis articulated robot, or the like. Theplurality of material handling systems 30, and their end effectors inparticular, may comprise multiple degrees of freedom, such as 6 degreesof freedom, to allow for the required picking (e.g., gripping,clutching, holding, positioning, rotating, and/or the like) the one ormore respective members 200 (e.g., one or more chords 222 and one ormore webs 238). Moreover, the plurality of material handling systems 30,and their end effectors in particular, may be moved (e.g., actuated,controlled, and/or operated) via an actuator (e.g., hydraulic,pneumatic, electric, and/or the like) of the plurality of materialhandling systems 30.

As discussed above, the plurality of material handling systems 30 maycomprise a plurality of chord material handling systems 32 that arestructured for loading (e.g., picking , transporting, positioning,and/or the like) one or more chords 222, such as one or more upperchords 224 and/or one or more lower chords 226. In this regard, therespective end effectors (also referred to as material handlinggrippers) of the plurality of chord material handling systems 32 arestructured to pick (e.g., grip, clutch, position, rotate, and/or thelike) the chords 222, without interference from or without interferingwith the respective material supply station 40, and chord projections(14 a, 14 b) (described in further detail later) and other staging andtooling components of the rigging table system 10. Similarly, theplurality of material handling systems 30 may further comprise aplurality of web material handling systems 34 that are structured forloading (e.g., picking, transporting, positioning, or the like) the oneor more web members 238. In this regard, the respective end effectors(also referred to as material handling grippers) of the plurality of webmaterial handling systems 34 are structured to pick (e.g., grip, clutch,position, rotate, and/or the like) the web members 238, withoutinterference from or without interfering with the respective materialsupply station 40, and web jigs 18, chord projections (14 a, 14 b)(described in further detail later) and other staging and toolingcomponents of the rigging table system 10. Moreover, in someembodiments, the end effectors (also referred to as material handlinggrippers) of the plurality of web material handling systems 34 arestructured such that undesirable movement of web members 238 during theloading (e.g., picking, transporting, positioning, or the like) process,even during high speed movements, is restricted. Moreover, in someembodiments, the end effectors (also referred to as material handlinggrippers) of the plurality of web material handling systems 34 arestructured to pick web members 238 of a variety of web lengths, andusing a variety of grips such grip low, grip high, or the like.

In some embodiments, the plurality of material handling systems 30,and/or a controller 450 (described in further detail later) associatedwith the plurality of material handling systems 30 and/or the joistassembly system 1 are structured to measure a picking location and timefor each of the chords 222 and/or web members 238 from their respectivematerial supply station 40. In some embodiments, the plurality ofmaterial handling systems 30, and/or the controller 450 may constructand utilize a same path for loading and transport of web members 238 ofall web lengths. In some embodiments, the plurality of material handlingsystems 30, and/or the controller 450 may optimize a path for loading ofweb members 238 of all web lengths. In some embodiments, the pluralityof material handling systems 30, and/or the controller 450 may constructand utilize varying paths for loading of web members 238 of varying weblengths.

In some embodiments the joists 220 (e.g., chords 222 and/or web members238) thereof may have bracing clips (e.g., paddle clips, or the like)that are used for cross-bracing between joists 220 when the joists 220are installed in a building. Moreover, the joists 220 (e.g., chords 222and/or web members 238) may have spacers (e.g., fillers, or the like)that are used to space the first upper chord portion 224 a apart fromthe second upper chord portion 224 b and/or the first lower chordportion 226 a apart from the second lower chord portion 224 b. It shouldbe understood that in some embodiments, the bracing clips (notillustrated) and/or the spacers (not illustrated) may be installed onthe chords 222 and/or webs 238 prior to being delivered to the materialsupply station 40. In some embodiments, the bracing clips and/or spacersmay be operatively coupled to the chords 222 and/or webs 238 prior tothe chords 222 and/or webs 238 being provided to the material supplystation 40, within the material supply station 40, and/or after thematerial supply station 40. The bracing clips may be operatively coupled(e.g., welded, or the like) by users physically welding the bracingclips to the chords 222 and/or webs 238. In some embodiments, a locatingsystem (not illustrated) having a laser, light curtain, etcher, markingdevice, or the like may mark locations on the chords 222 and/or webs 238in order to indicate where the bracing clips and/or spacers should beoperatively coupled to the chords 222 and/or webs 238. The users maypre-assemble or post-assemble the bracing clips to the chords 222 and/orwebs 238. The users may also pre-assemble the spacers to the chords 222.In this way, it should be understood that the pre-welding of the bracingclips and/or spacers may improve the throughput of the joist assemblysystem 1. That is, the pre-welding may reduce the number of operations(e.g., welding operations, positioning operations, or the like) that areperformed by the joist assembly system 1, thus reducing the assemblytime of the joist 220 within the joist assembly system 1.

Alternatively, in some embodiments the bracing clips and/or spacers maybe positioned automatically by the material handling systems 30 and/orautomatically welded by the welding systems 60. As such, the pluralityof material handling systems 30, and/or a controller 450 associated withthe plurality of material handling systems 30 and/or the joist assemblysystem 1 may be structured to determine a picking location and time forthe predetermined small parts (e.g., bracing clips, spacers, or thelike) associated with the joist 220 from their respective materialsupply station 40. The plurality of material handling systems 30, and/orthe controller 450 may place the bracing clip (e.g., paddle clip, or thelike) within a placement tolerance of about +/−1 inches along a lineardirection and/or a bracing clip placement tolerance of about −⅛ to 0inches from top and bottom chord faces, and may place the spacer (e.g.,filler, or the like) within a placement tolerance of about +/−2 inchesin a linear direction and/or a spacer placement tolerance of about 0 to0.25 inches inboard from far side chord face.

In some embodiments, the plurality of material handling systems 30 arestructured to move through placement of respective chords 222 and/or webmembers 238 in a semi-coordinated and/or fully-coordinated motion. Inthis regard, a controller 450 associated with the plurality of materialhandling systems 30 and/or the joist assembly system 1 may determine orconstruct cycle times for assembling the joists 220 (e.g., retrieval,transport, positioning, joining, assembly, and/or the like steps) foreach of the chords 222 and/or web members 238, and coordinate movementand actions of the plurality of chord material handling systems 32 andplurality of web material handling systems 34, accordingly. In someembodiments, the plurality of material handling systems 30 may beconfigured to place and position the respective chords 222 and/or webmembers 238 onto the respective locations of the rigging table system 10at a predetermined maximum speed of semi-coordinated motion, while inother embodiments, the plurality of material handling systems 30 mayswitch to a predetermined medium or slow speed (or a soft speed mode)for certain steps such as positioning of the respective chords 222and/or web members 238 onto the respective locations of the riggingtable system 10.

Moreover, the plurality of material handling systems 30 are configuredfor loading respective chords 222 and/or web members 238 within apredetermined tolerance. In this regard, the plurality of materialhandling systems 30 may be associated with or configure an outlinewindow and repeatedly place the respective chords 222 and/or web members238 within the window at a predetermined high speed. The plurality ofmaterial handling systems 30 are further configured to detect anycollisions (and/or prevent subsequent collisions after a collision hasbeen detected). In some embodiments, the plurality of material handlingsystems 30 are associated with a web member 238 placement tolerance ofabout +/−0.5 inches along a linear direction. In some embodiments, theplurality of material handling systems 30 are associated with a webmember 238 placement tolerance of about +/−0.01, +/−0.05, +/−0.1 ,+/−0.2, +/−0.3, +/−0.4, +/−0.5, +/−0.6, +/−0.7, +/−0.8, +/−0.9, and/or+/−1 inches, along a linear direction, and/or within a tolerance rangewith any combination of limits selected from the foregoing. In someembodiments, the plurality of material handling systems 30 areassociated with a web member 238 placement tolerance of about −0.25 to+0 inches with respect to top and bottom chord faces. In someembodiments, the plurality of material handling systems 30 areassociated with a web member 238 placement tolerance of about −0.1 to+0.1 inches, −0.2 to +0.2 inches, −0.5 to +0.5 inches, −0.25 to +0.1inches, −0.2 to +0.1 inches, −0.25 to +0.25 inches, −0.3 to +0.3 inches,−0.5 to +0.5 inches, −0.5 to +0.1 inches, −0.4 to +0.1 inches, and/or −1to +0.5 inches, with respect to top and bottom chord faces, and/orwithin a tolerance range with any combination of limits selected fromthe foregoing.

As discussed, the material handling system 30 may hold or maintain thechords 222 and/or web members 238 in their correct position/orientationwhile a plurality of welding systems 60 join (e.g., weld) the componentsor members 200 together, thereby precluding any undesirable displacementduring the joining process. Here, the plurality of material handlingsystems 30 may further apply a predetermined downward force onto thechords 222 and/or web members 238 in their correct position/orientationover the rigging table system 10 during the joining process. Thecontroller 450 associated with the plurality of material handlingsystems 30 and/or the joist assembly system 1 may determine/measure anapplied downward force (e.g., a human downward force duringconfiguration) and fit-up. The controller 450 may then compare adownward force associated with the plurality of material handlingsystems 30, and control the plurality of material handling systems 30such that the downward force of the plurality of material handlingsystems 30 meets or exceeds the applied downward force (e.g., a humandownward force during configuration). Moreover, the control may verifycontact between a web member 238 and a respective top/bottom chord 222,when positioned for assembly on the rigging table system 10.

In some embodiments, the plurality of material handling systems 30 arestructured for camber match (e.g., via a soft speed mode). In thisregard, the controller 450 may utilize a largest chord 222 to simulatethe foregoing. The controller 450 may verify contact with the chordmembers 222 using camber match tooling (e.g., associated with therigging table system 10 such as chord projections (14 a, 14 b), and/orweb jigs 18). The controller 450 may further verify contact with webmembers 238 from the applied downward force, which in some embodiments,may be based on determining consistent web members 238, not touchingevery web member 238, and/or a gap tolerance of +/−⅛ inches on sidechords 222 (e.g., straight chords).

In some embodiments, the plurality of material handling systems 30and/or the controller 450 may measure structure deflection during theloading (e.g., retrieval, placement, or the like) processes. Moreover,the plurality of material handling systems 30 and/or the controller 450may minimize the deflection such that the placement of the chords 222and/or the web members 238 is not adversely affected.

Rigging Table System

As illustrated by FIGS. 1-22, the joist assembly system 1 of the presentinvention comprises a rigging table system 10. Typically, the riggingtable system 10 supports the chords 222 or webs 238 positioned thereon(e.g., by the plurality of material handling systems 30). Subsequently,the plurality of welding systems 60 may join (e.g., weld) the webs 238to the chords 222 to form the joist 220. The assembled joist 220 maythen be discharged from the rigging table 1 and transported therefrom.In some embodiments, the rigging table system 10 comprises a generallyelongate arrangement extending from a first table end 82 to an oppositesecond table end 84. The rigging table system 10 may define a firsttable side 12 a (e.g., a first lateral side) and an opposite secondtable side 12 b (e.g., a second lateral side). Moreover, the riggingtable system 10 may be positioned at the first level 96 over the supportfloor 92 and extend to a height between the support floor 92 and thesecond level 98.

In some embodiments, the rigging table system 10 comprises a pluralityof upper chord projections 14 a spaced apart to form a plurality ofupper chord cavities 16 a. The plurality of upper chord projections 14 atogether with the plurality of upper chord cavities 16 a are structuredto hold and support a chord 222 such as a first upper chord portion 224a of an upper chord 224. Moreover, the rigging table system 10 comprisesa plurality of lower chord projections 14 b spaced apart to from aplurality of lower chord cavities 16 b. The plurality of lower chordprojections 14 b together with the plurality of lower chord cavities 16b are structured to hold and support a chord 222 such as a first lowerchord portion 226 a of a lower chord 226. Moreover, the plurality ofupper chord projections 14 a and/or the plurality of lower chordprojections 14 b allow the first upper chord portion 224 a of the upperchord 224 to be spaced different distances apart from the first lowerchord portion 226 a of the lower chord 226 to allow for assembly of ajoist 220 of any required dimensions. Moreover, the rigging table system10 may comprise a plurality of web jigs 18 that are structured to holdand support web members 238, at any required orientation, inclinationand location with respect to each other and with respect to the chords222. In some embodiments, a controller 450 associated with the pluralityof material handling systems 30 and/or the joist assembly system 1 maytrigger or cause positioning the chords 222 and web members 238 on therigging table system 10 in accordance with programmed joist parametersfor the assembled joist 220. As such, in some embodiments web jigs 18may be used to position the webs members 238; however, in someembodiments the web members 238 are positioned and held in place only bythe material handling system 30. As discussed, the joist parameters maycomprise minimum joist size, maximum joist size, minimum depth, maximumdepth, and maximum or minimum chord length, chord depth, web positionand orientation, weld lengths, and/or the like.

In some embodiments, the rigging table system 10, and/or the pluralityof upper chord projections 14 a, plurality of lower chord projections 14ba, and/or web jigs 18 thereof, comprise stop members (e.g., pneumaticcamber induction drives, or the like) structured to provide a hard stopfor all chord sizes at reduced operating pressure (e.g., associated witha predetermined safety factor).

The rigging table system 10 further comprises a discharging system 50.Typically, the discharging system 50 comprises plurality of rollers 52that may be retracted to allow for positioning of the components ormembers 200 such as chords 222 and webs 238 onto the rigging tablesystem 10, and extended in an upward direction to allow for dischargeand transport of an assembled joist 220 after the joining (e.g.,welding, or the like) process. In this regard, the discharging system 50is structured to move the assembled joist 220 after the joining (e.g.,welding, or the like) from the rigging table system 10, and/or from theplurality of upper chord projections 14 a, plurality of lower chordprojections 14 ba, and/or web jigs 18 thereof at reduced operatingpressure (e.g., associated with a predetermined safety factor).

Welding Systems

As illustrated by FIGS. 1-20, the joist assembly system 1 of the presentinvention comprises plurality of welding systems 60 that are structuredto join, e.g., via welding, the members 200 such as chords 222 and webs238 positioned on the rigging table system 10. The joining (e.g.,welding, or the like) may be performed in accordance with the requiredjoist parameters. The plurality of welding systems 60 may be provided atthe first level 96 (e.g., over the support floor 92). Moreover, theplurality of welding systems 60 may comprise a plurality of firstwelding systems 62 provided proximate the first table side 12 a of therigging table system 10, and plurality of second welding systems 64provided proximate the second table side 12 b of the rigging tablesystem 10. In other words, the rigging table system 10 may be positionedbetween the plurality of first welding systems 62 and the plurality ofsecond welding systems 64. That said, more or fewer welding systems maybe provided. Typically, each of the plurality of welding systems 60comprise welding arms that are structured to extend over the riggingtable system 10 and join (e.g., weld) members 200 such as chords 222 andwebs 238 positioned thereon. In some embodiments, the plurality ofwelding systems 60 may be structured for arc welding, laser welding,brazing, or the like in order to form the joist 220. In otherembodiments, the welding system 60 may be joining systems 60 thatprovide for other joints other than welding, such as riveting,self-taping and/or self-drilling fasteners, other fasteners that areinserted into an aperture, and/or other joining operations to form thejoist 220.

Typically, the plurality of welding systems 60 comprise a defaultretracted position. The plurality of welding systems 60, and/or weldingarms thereof, are structured move from the default position to reachside to side to cover a predetermined associated work area (alsoreferred to as a work envelope) thereby moving to a joining position (ora welding position). Here, the plurality of first welding systems 62 maybe associated with work areas proximate the first table side 12 a of therigging table system 10, while the plurality of second welding systems64 may be associated with work areas proximate the second table side 12b of the rigging table system 10. The time for the movement of theplurality of welding systems 60, and/or welding arms thereof from thedefault position to the joining position may be measured by thecontroller 450.

In some embodiments, each of the plurality of welding systems 60 may beassociated with a maintenance position, such as a torch maintenanceposition. The plurality of welding systems 60 may be associated with atorch maintenance cycle which may be performed after the joining/weldingprocess is complete. For example, the torch welding maintenance positionmay be used for cleaning the nozzle of the welding robot between weldingof one or more joists 220 (e.g., between each joist, or a run of two ormore joists). As such, during or after the joist 220 is discharged fromthe rigging table system 10, the welding systems 60 move from thejoining position and/or a retracted position into a torch maintenanceposition. In some embodiments the torch maintenance position may occurin the retracted position. In the torch maintenance position, thewelding tips of the welding systems 60 may be cleaned (e.g., using wirebrushes, cleaning solution, or the like).

Moreover, the plurality of welding systems 60 are collectivelystructured to reach all the weld locations of the joist 220. In thisregard, a minimum reach or range or depth of each of the plurality ofwelding systems 60 may be around 20 inches. Moreover, the plurality ofwelding systems 60 are associated to perform the associated joiningprocess such as welding in accordance with joining parameters such asweld depth. In some embodiments, the plurality of welding systems 60 mayperform the associated joining process such as welding in accordancewith weld criteria such as preventing/minimizing surface bubbles orcracks, maximum allowed undercutting of about 0.03 or 0.03125 inches,preventing/minimizing gouges or nicks, maximum sum of surface piping(porosity) not exceeding 1/16 inches in any 1 inch of weld, welds notbeing less than the material thickness for webs less than ¼ inch thick,otherwise the weld being the material thickness − 1/16 inches, themaximum single pass weld being 5/16 inches, or the like.

Operation of the Joist Assembly System

The functioning of the joist assembly system 1 will now be described indetail. Specifically, FIG. 1 illustrates the plurality of chord materialhandling systems 32 of the plurality of material handling systems 30loading a first upper chord 224 and a first lower chord 226 fromlocation “X” at a first picking location 42 of the material supplystation 40 and transporting it towards the rigging table system 10. FIG.1 illustrates the first upper chord 224 and the first lower chord 226 atan intermediate position “Y” in between the transport path from thechord supply location X to the rigging table system 10. FIG. 3Aillustrates a portion of the plurality of chord material handlingsystems 32 picking an upper chord 224 from its supply location X at afirst picking location 42 of material supply station 40. The pluralityof chord material handling systems 32 then transport the upper chord 224towards the rigging table system 10 as illustrated by FIG. 3B.

The plurality of chord material handling systems 32 may then positionthe retrieved first upper chord 224 and first lower chord 226 at therigging table system 10 at an assembly location “Z”, as illustrated byFIG. 4. Here, as illustrated, the first upper chord 224 may bepositioned proximate the first table side 12 a of the rigging tablesystem 10 and the first lower chord 226 may be positioned proximate thesecond table side 12 b of the rigging table system 10, with the firstupper chord 224 and the first lower chord 226 being spaced apart by apredetermined distance.

FIG. 5A illustrates a detail view of the first upper chord 224 and thefirst lower chord 226 at an intermediate position “Y” in between thetransport path from supply location X to the rigging table system 10. Asillustrated by FIG. 5B, before and/or during the transport of the chords222 towards the rigging table system 10, the plurality of rollers 52 ofthe discharging system 50 may be in an extended position from apreceding discharge cycle from a discharge/transport of a priorassembled joist out of the rigging table system 10. Next, as illustratedby FIGS. 6A and 6B, as the plurality of chord material handling systems32 move the first upper chord 224 and the first lower chord 226 from theintermediate position Y towards the rigging table system 10, theplurality of rollers 52 retract, allowing for positioning of the chordsand other elements required for the next assembly cycle. FIGS. 5A-6Bfurther illustrate chord projections (14 a, 14 b) and chord cavities (16a, 16 b) provided at the rigging table system 10.

Next, plurality of chord material handling systems 32 load the firstupper chord 224 and the first lower chord 226 at the rigging tablesystem 10 as illustrated by FIG. 7A. As depicted by the detail view ofFIG. 7B, the first upper chord 224 is positioned at the plurality ofupper chord projections 14 a such that first upper chord portion 224 ais at least partially within the plurality of upper chord cavities 16 a.In other words, the first upper chord 224 is held in place and supportedby the plurality of upper chord projections 14 a in conjunction with theplurality of upper chord cavities 16 a. Moreover, the first lower chord226 is positioned at the plurality of lower chord projections 14 b suchthat first lower chord portion 226 a is at least partially withinplurality of lower chord projections 14 b. In other words, the firstlower chord 226 is held in place and supported by the plurality of lowerchord projections 14 b in conjunction with the plurality of lower chordcavities 16 b. Subsequently, the plurality of chord material handlingsystems 32 of the plurality of material handling systems 30 may retractaway from the rigging table system 10 as illustrated by FIG. 8. In someembodiments, one or more retaining members (e.g., clamps, fingers, orthe like) may actuate to restrict the movement of the chords 222 (e.g.,clamp the chords in place).

Next, the plurality of material handling systems 30 may load (e.g.,retrieve, transport, position, or the like) a first set of web members238 from the material supply station 40. In this regard, FIG. 9illustrates the plurality of web material handling systems 34 grip afirst set of web members 238 at second picking location 44 of thematerial supply station 40. Next, FIG. 10 illustrates the plurality ofweb material handling systems 34 retracting from the material supplystation 40, thereby transporting the first set of web members 238towards the rigging table system 10. In some embodiments, the pluralityof web material handling systems 34 may turn, rotate, and/or otherwiseorient the web members 238 in accordance with the required structure ofthe joist 222, while the web members 238 are being transported towardsthe rigging table system 10.

Next, the plurality of web material handling systems 34 position thefirst set of web members 238 at the rigging table system 10 between thealready positioned first upper chord 224 and first lower chord 226, asillustrated by FIG. 11A. As depicted by the detail view of FIG. 11B, thefirst set of web members 238 are positioned by the web material handlingsystems 34 (e.g., with our without web jigs 18) at a predeterminedposition, angle, spacing, and/or the like in accordance with therequired structure of the joist 220. Moreover, the web members 238 maybe positioned relative to the upper chord 224 and lower chord 226 suchthat each of the web members 238 forms at least one joining location(e.g., welding location) with the upper chord 224 and/or the lower chord226. Here, at least a portion of each end of each of the web members 238may be positioned to be proximate (e.g., contact, overlap, or the like)an adjacent portion of the upper chord 224 and/or the lower chord 226 tothereby form the joining location(s) to facilitate joining (e.g.,welding) of the pair of the web member 238 and the corresponding theupper chord 224 and/or the lower chord 226 at the joining locations.

Next, the plurality of welding systems 60 may move from their defaultretracted position to a joining position, (e.g., extend to move over acover a predetermined associated work area, also referred to as a workenvelope) over the rigging table system 10, as illustrated by FIG. 12A.The plurality of web material handling systems 34 may hold or maintainthe web members 238 and/or the upper chord 224 and/or the lower chord226 in their correct position (e.g., location, orientation, pressure, orthe like) while the plurality of welding systems 60 join (e.g., weld)the components or members 200 together, thereby precluding anyundesirable displacement during the joining process. As such, theplurality of web material handling systems 34 may apply a predetermineddownward force onto the web members 238 and/or the upper chord 224and/or the lower chord 226 in their correct position over the riggingtable system 10 during the joining process. Moreover, as illustrated bythe detail view of FIG. 12B, the plurality of first welding systems 62may join (e.g., weld) joint locations Ja between the upper chord 224 andcorresponding ends of the web members 238, while the plurality of secondwelding systems 64 may join (e.g., weld) the lower chord 226 andcorresponding ends of the web members 238 at the joining locations Jb.The plurality of first welding systems 62 and plurality of secondwelding systems 64 may subsequently move back to the default retractedpositions.

Next, the plurality of web material handling systems 34 may retract andmove towards the material supply station 40 to load a second set of webmembers 238′ from the material supply station 40. In this regard, FIG.13 illustrates the plurality of web material handling systems 34 grip asecond set of web members 238′ at the second picking location 44 of thematerial supply station 40. Next, FIG. 14 illustrates the plurality ofweb material handling systems 34 transporting the second set of webmembers 238′ towards the rigging table system 10. In some embodiments,the plurality of web material handling systems 34 may turn, rotate,and/or otherwise orient) the web members 238′ in accordance with therequired structure of the joist, while the web members 238′ are beingtransported towards the rigging table system 10. Next, the plurality ofweb material handling systems 34 position the second set of web members238′ at the rigging table system 10 between the already positioned firstupper chord 224 and first lower chord 226 and adjacent alreadypositioned first set of web members 238, as illustrated by FIG. 15. Thesecond set of web members 238′ may also be positioned (e.g., with ourwithout web jigs 18) at a predetermined position, angle, spacing, and/orthe like in accordance with the required structure of the joist.Moreover, the web members 238′ may be positioned relative to (i) theupper chord 224 and lower chord 226, and/or (ii) the first set of webmembers 238 such that each of the web members 238′ forms at least onejoining location with the upper chord 224 and/or the lower chord 226and/or a web member of the first set of web members 238. Here, at leasta portion of each end of each of the web members 238′ may be positionedto be proximate (e.g., contact, overlap, or the like) an adjacentportion of the upper chord 224 and/or the lower chord 226 to therebyform the joining location(s) to facilitate joining (e.g., welding) ofthe pair of the web member 238′ and the corresponding the upper chord224 and/or the lower chord 226 at the joining position. Moreover, thesecond set of web members 238′ may similarly form joining locations withthe first set of web members 238.

Next, the plurality of welding systems 60 may move from their defaultretracted position to a joining position (e.g., extend to move over acover a predetermined associated work area, also referred to as a workenvelope) over the rigging table system 10, as illustrated by FIGS. 15and 16. The plurality of first welding systems 62 and plurality ofsecond welding systems 64 may join (e.g., weld) the second set of webmembers 238′ to the upper chord 224, lower chord 226, and/or the firstset of web members 238. The plurality of web material handling systems34 may hold or maintain the second set of web members 238′ in theircorrect position (e.g., location, orientation, pressure, or the like)while the plurality of welding systems 60 join (e.g., weld) thecomponents or members 200 together, thereby precluding any undesirabledisplacement during the joining process. As such, the plurality of webmaterial handling systems 34 may apply a predetermined downward forceonto the second set of web members 238′ in their correct position overthe rigging table system 10 during the joining process.

It should be understood that in some embodiments, a third set of webmembers 238″ (e.g., vertical web members when the joist is installed)are loaded and joined as previously described with respect to the firstset of web members and second set of web members (e.g., diagonal websmembers when the joist is installed). In some embodiments, during thewelding process the material handling systems 30 (e.g., the web materialhandling systems 34) may only hold the web members 238 long enough to betack welded (e.g., a 1, 2, 3, 4, 5, or the like millimeters of weld)such that the web members 238 cannot move with respect to the chordsmembers 222. After the members are tack welded, the material handlingsystems 30 (e.g., the chord material handling systems 34) may releasethe web member 238 in order to return to the second picking location 44in order to load more webs. As the same time, the welding systems 60continue to weld the webs 238 to the chords 222 after the tack welding.

It should be further understood that one or more sensors may be usedthroughout the joist assembly system 1. The sensors may be any type ofsensor that is used for various purposes, such as but not limited tochecking the size and/or position of the chords 222 and/or webs 238,checking the welds on the joists 220, checking the location of thedevices within the joist assembly system 1, identifying foreign objects(e.g., people, members that should not be present, or the like) in thejoist assembly system 1, or the like. In some embodiments of theinvention, the sensors (e.g., a web sensor system, chord sensor system,not illustrated) may be utilized to identify the web members 238, chordmembers 222, or the like. For example, the sensors (e.g., laser sensors,or the like) may identify the web members 238 (e.g., based on the lengthof the web members 238) in order to make sure the correct webs have beenprovided in the materials supply station 40. Moreover, the sensors mayidentify the position of the web members 238 when loaded on the table inorder to identify if they have been placed in the proper location (e.g.,to adjust welding if needed). Additionally, the sensors may also detectif the chord members 222 are present and/or have been loaded properly(e.g., and stop the joist assembly system 1, if the incorrect websmembers 238 or chord members 222 have been used or positioned, and/orare not present). Furthermore, sensors (e.g., lasers, or the like) maybe used to locate where additional parts should be located (e.g.,bracing clips, spacers, or the like) that may be assembled manually.Should the sensors identify a potential issue with any of the foregoing,an alert may be sent to a user, the operation of the joist assemblysystem 1 (or particular device thereof) may be adjusted (e.g., stoppedor slowed down). Furthermore, it should be understood that the weldingparameters (e.g., time, filler used, route of the welding tip,temperature, or the like may be monitored for each of the weldingsystems 60) in order to capture data about the welding process for eachjoist, which may allow the controller 450 to determine if there are anyanomalies that occurred in the welding process.

Computer systems (e.g., user computer systems 420) may be providedwithin, upstream, and/or downstream of the joist assembly system 1 inorder to provide operating information to the users. The informationdisplayed may include any alerts identified by the controller 450 in thejoist assembly system 1, that may require a user to take an action withrespect to a joist 220 and/or the joist assembly system 1. For example,graphical user interfaces may illustrate to users if there are anypotential errors in the welds that may require inspection and/or repairafter the joist 220 has been discharged from the joist assembly system1.

In other embodiments of the invention, the welding systems 60 may bereplaced or supplemented by other methods of the joining the websmembers 238 to the chord members 222. For example, fasteners may be usedin order to join the web members 238 to the chord members 222. As such,other joining systems may be implemented should other types of joiningof the web members 238 and chord members 222 be utilized.

After welding of the web members 238, the plurality of chord materialhandling systems 32 of the plurality of material handling systems 30 mayload (e.g., retrieve, transport, position, or the like) a second upperchord 224′ and a second lower chord 226′ from the first picking location42 of material supply station 40. FIG. 16 illustrates the plurality ofchord material handling systems 32 grip a second upper chord 224′ and asecond lower chord 226′ from its storage location at first pickinglocation 42 of the material supply station 40. FIG. 17 illustrates thesecond upper chord 224′ and the second lower chord 226′ at anintermediate position in between the transport path from the firstpicking location 42 to the rigging table system 10. The plurality ofchord material handling systems 32 may then position the retrievedsecond upper chord 224′ and second lower chord 226′ at the rigging tablesystem 10, as illustrated by FIG. 18. As such, as illustrated, thesecond upper chord 224′ may be positioned over the existing first upperchord 224 and the second lower chord 226′ may be positioned over theexisting lower chord 226 at the rigging table system 10, with the secondupper chord 224′ and the second lower chord 226′ being spaced apart by apredetermined distance. The second upper chord 224′ may be held in placeand supported by the plurality of upper chord projections 14 a inconjunction with the plurality of upper chord cavities 16 a, while thesecond lower chord 226′ maybe held in place and supported by theplurality of lower chord projections 14 b in conjunction with theplurality of lower chord cavities 16 b, similar to the manner describedpreviously with respect to the first upper and lower chords (224, 226).Subsequently, the plurality of chord material handling systems 32 of theplurality of material handling systems 30 may retract away from therigging table system 10.

Next, the plurality of welding systems 60 may move from their defaultretracted position to a joining position (e.g., extend to move over acover a predetermined associated work area, also referred to as a workenvelope) over the rigging table system 10, as illustrated by FIGS. 19Aand 19B. The plurality of first welding systems 62 and plurality ofsecond welding systems 64 may join (e.g., weld) the second upper chord224′ and the second lower chord 226′ to the upper chord 224, lower chord226, the first set of web members 238, the second set of web members238′, spacers, and/or a third set of web members, to thereby form thejoist 220. The plurality of welding systems 60 may then move to thedefault retracted position and/or to a maintenance position.

The discharge process of the constructed joist 220 from the riggingtable system 10 will now be described in further detail. In someembodiments of the invention, the discharging system 50 may comprise aplurality of rollers 52. As illustrated by the detail view in FIG. 19B,during or immediately upon assembly of the joist 220, the plurality ofrollers 52 of the discharging system 50 may be in a retracted position54. Next, as illustrated by FIG. 19C, the plurality of rollers 52 mayextend upwards (e.g., out of cavities of the rigging table system 10 inwhich the joist 220 rests. In this way, the extending or extendedplurality of rollers 52 may cause the joist 220 to be released from theplurality of upper chord projections 14 a, plurality of lower chordprojections 14 b (and the web jigs 18, if utilized), and lift the joist220 at least partially above the rigging table system 10. Next, rotationof the plurality of rollers 52 may be activated which causes lineardisplacement or discharge of the joist 220 out of the rigging tablesystem 10, as illustrated by FIG. 20. The discharged joist 220 may thenbe lifted and transported to the desired location. The process may berepeated to form additional joists 220.

Web and Chord Supply Systems

As previously discussed herein, the material supply station 40 maycomprise a web supply system 302, as illustrated in FIGS. 21A and 21B,and/or a chord supply system 304. The web supply system 302 may comprisea web supply track 310, a web supply carriage 320, and a web supplyrobot 330. The web supply carriage 320 may move with respect to the websupply track 310, and the web supply robot 330 may move in multipledegrees of freedom, as previously described with respect to other robotsdescribed herein. As such, the web supply system 300 may receive webmembers 238 from adjacent the support structure 94 provided on a supportfloor 92 (e.g., adjacent a first level 96 located proximate the supportfloor 92) as illustrated in FIG. 21A, and thereafter, deliver the webmembers 238 to the material supply station 40 (e.g., at the secondpicking location 44) as illustrated in FIG. 21B.

In some embodiments, the material supply station 40 may further comprisea chord supply system 304 as illustrated in FIG. 22. The chord supplysystem 304 may include a conveyor 350 (e.g., track, rollers, belt, orthe like) that moves the chords from adjacent the support structure 94(e.g., adjacent a first level 96, adjacent a second level 98, or thelike) and delivers the chord members 222 to the material supply station40 (e.g., at the first picking location 42). In alternate embodiments,the chord supply system 304 may be similar to the web supply system 302.In some embodiments the chord supply system 304 and the web supplysystem 302 may be a single system that allows for the delivery of boththe web members 238 and the chord members 220 to the material supplystation 40.

Controller Systems

The operation of the joist assembly system 1, including the plurality ofmaterial handling systems 30, a plurality of welding systems 60, thematerial supply stations 40 (e.g., including the chord and/or web supplysystems 300), the rigging table system 10, and/or the like, and thedevices (e.g., robots, carriages, actuators, weld feeders, weld tipcleaners, or the like), are controlled by a programmable controller 450,which may communicate with other systems within or outside of afacility. As such, FIG. 23 illustrates a joist assembly network system400, in accordance with embodiments of the present disclosure. Asillustrated in FIG. 23, one or more controller systems 410 areoperatively coupled, via a network 402, to one or more user computersystems 420, one or more device systems 430 (e.g., systems that controlthe robots, carriages, actuators, weld feeders, weld tip cleaners, orthe like of the joist assembly system 1), and/or one or more othersystems (not illustrated). In this way, the controller systems 410operating the joist assembly system 1 may communicate with one or moredevice systems 430 for assembling the joists as described herein. Thecontroller systems 410 may communicate with user computer systems 420 toallow the users of the user computer systems 420 to monitor the joistassembly system 1. Moreover, the controller systems 410 may communicatewith other systems, such as other systems of other machinery in thefacility and/or other systems outside of the facility (e.g., orderingsystems, third party systems, or the like) to determine what chords 222and/or webs 238 need to be provided to joist assembly system 1. Thecommunications may occur over a network 402, as will be described infurther detail herein.

The network 402 may be a global area network (GAN), such as theInternet, a wide area network (WAN), a local area network (LAN), or anyother type of network or combination of networks. The network 402 mayprovide for wireline, wireless, or a combination of wireline andwireless communication between systems, services, components, and/ordevices on the network 402.

As illustrated in FIG. 23, the one or more controller systems 410 maycomprise a controller 450 that may generally comprise one or morecommunication components 412, one or more processing components 414, andone or more memory components 416. The one or more processing components414 are operatively coupled to the one or more communication components412, and the one or more memory components 416. As used herein, the term“processing component” generally includes circuitry used forimplementing the communication and/or logic functions of a particularsystem. For example, a processing component may include a digital signalprocessor component, a microprocessor component, and variousanalog-to-digital converters, digital-to-analog converters, and othersupport circuits and/or combinations of the foregoing. Control andsignal processing functions of the system are allocated between theseprocessing components according to their respective capabilities. Theone or more processing components may include functionality to operateone or more software programs based on computer-readable instructionsthereof, which may be stored in the one or more memory components.

The controller 450 components, such as the one or more communicationcomponents 412, may be operatively coupled to the one or more sensors440 (e.g., safety sensors, supply sensors, location sensors, lasersensors, or the like) as previously discussed herein) located within thejoist assembly system 1.

The one or more processing components 414 use the one or morecommunication components 412 to communicate with the network 402 andother components on the network 402, such as, but not limited to, thecomponents of the one or more user computer systems 420, the one or moredevice systems 430, and/or the one or more other systems (notillustrated). As such, the one or more communication components 412generally comprise a wireless transceiver, modem, server, electricalconnection, electrical circuit, or other component for communicatingwith other components on the network 402. The one or more communicationcomponents 412 may further include an interface that accepts one or morenetwork interface cards, ports for connection of network components,Universal Serial Bus (USB) connectors, or the like. Moreover, the one ormore communication components 412 may include a keypad, keyboard,touch-screen, touchpad, microphone, mouse, joystick, other pointercomponent, button, soft key, and/or other input/output component(s) forcommunicating with the users. In some embodiments, as described hereinthe one or more communication components 412 may comprise a userinterface, such as a graphical user interface 455 that allows a user tocontrol and/or monitor the operation of the joist assembly system 1.

As further illustrated in FIG. 23, the one or more controller systems410 comprise computer-readable instructions 418 stored in the one ormore memory components 416, which in some embodiments includes thecomputer-readable instructions 418 of the one or more controllerapplications 417 (e.g., used to operate the joist assembly system 1and/or the devices thereof, or the like). In some embodiments, the oneor more memory components 416 include one or more data stores 419 forstoring data related to the joist assembly system 1, including, but notlimited to, data created, accessed, and/or used by the one or morecontroller systems 410 to operate the one or more joist assembly systems1 in order to form the joists (e.g., in accordance with joistspecifications that may be stored, or the like).

As illustrated in FIG. 23, users may communicate with each other overthe network 402 and the controller systems 410, the device systems 430,and/or other systems in order to control and/or monitor the varioussystems at the joist assembly system 1 and/or remotely. Consequently,the one or more users may be assemblers, welders, employees, agents,representatives, officers, or the like of an organization operating thefacility. The one or more user computer systems 420 may be a desktop,laptop, tablet, mobile device (e.g., smartphone device, or other mobiledevice), or any other type of computer that generally comprises one ormore communication components 422, one or more processing components424, and one or more memory components 426. In some embodiments the oneor more computer systems 420 may be located upstream or downstream ofthe joist assembly system 1 and are used for pre-assembly and/orpre-inspections of the chords 222 and/or webs 238 (e.g., assembly of thebracing clips and/or spacers, or the like), and/or post assembly and/orpost-inspection of the joists 220 (e.g., complete the welding, inspectwelding, and/or the like).

The one or more processing components 424 are operatively coupled to theone or more communication components 422, and the one or more memorycomponents 426. The one or more processing components 424 use the one ormore communication components 422 to communicate with the network 402and other components on the network 402, such as, but not limited to,the one or more controller systems 410, the one or more device systems430, and/or the other systems (not illustrated). As such, the one ormore communication components 422 generally comprise a wirelesstransceiver, modem, server, electrical connection, or other componentfor communicating with other components on the network 402. The one ormore communication components 422 may further include an interface thataccepts one or more network interface cards, ports for connection ofnetwork components, Universal Serial Bus (USB) connectors and the like.Moreover, the one or more communication components 422 may include akeypad, keyboard, touch-screen, touchpad, microphone, mouse, joystick,other pointer component, button, soft key, and/or other input/outputcomponent(s) for communicating with the users. In some embodiments, theone or more communication components 422 may comprise a user interface,such as a graphical user interface that allows a user to remotelycontrol and/or monitor the operation of the joist assembly system 1.

As illustrated in FIG. 23, the one or more user computer systems 420 mayhave computer-readable instructions 428 stored in the one or more memorycomponents 426, which in some embodiments includes the computer-readableinstructions 428 for user applications 427, such as dedicatedapplications (e.g., apps, applet, or the like), portions of dedicatedapplications, a web browser or other apps that allow access toapplications located on other systems, or the like. In some embodiments,the one or more memory components 426 include one or more data stores429 for storing data related to the one or more user computer systems420, including, but not limited to, data created, accessed, and/or usedby the one or more user computer systems 420. The user application 427may use the applications of the one or more controller systems 410, theone or more product systems 430, and/or one or more other systems (notillustrated) in order to communicate with other systems on the network402 and take various actions described herein (e.g., operation, use,monitoring, or the like the joist assembly system 1).

Moreover, as illustrated in FIG. 23, the one or more device systems 430and/or other systems (not illustrated) have components the same as orsimilar to the components described with respect to the one or morecontroller systems 410 and the one or more user computer systems 420(e.g., one or more communication components, one or more processingcomponents, one or more sensors, one or more memory devices withcomputer-readable instructions of one or more product applications, oneor more datastores, or the like). Thus, the one or more device systems430 communicate with the one or more controller systems 410, the one ormore user computer systems 420, and/or one or more other systems in thesame or similar way as previously described with respect to the one ormore controller systems 410, the one or more user computer systems 420,and/or the one or more other systems. The one or more device systems 430may comprise the systems that operate the machines (e.g., robots,carriages, rollers, actuators, or the like) of the joist assembly system1 that are used to assemble the joists 220.

Process of Forming a Joist

FIG. 24 illustrates a process flow for assembling a joist 220 using thejoist assembly system 1 described herein. As illustrated by block 502,the specifications for a joist are selected. The specifications may bestored in the controller systems 410. For example, a user may storespecifications for different types of joists 220, and a user may selectone joist of the plurality of joists for assembly, or otherwise mayselect one or more specifications in order to determine the joist 220 tobe assembled. The controller 450 uses the specifications in order todetermine how to operate the joist assembly system 1 for assembling thejoist 220 selected.

Block 504 of FIG. 23 further illustrates that the chords 222 and/or webs238 are provided to the supply systems 300 (e.g., webs supply system302, chord supply system 304, or the like). The chords 222 and/or webs238 may have bracing clips, spacers, and/or other componentspre-assembled before, during, or after delivery to the supply systems300.

FIG. 23 further illustrates in block 506 that the supply systems 300deliver the chords 222 and/or webs 238 to the material supply station40. As previously discuss herein the material supply station 40 may belocated at least partially above the rigging table system 10. In someembodiments the chords 222 and/or web 238 may already be located in thematerial supply station when the user makes the selection of aspecification for a joist 220.

Block 508 illustrates that the rigging table system 10 may be adjustedbased on the type of joist 220 being assembled (e.g., the projections ofthe rigging table may be adjusted farther apart or closer together forreceipt of the first upper and lower chords). The adjustment may occurmanually and/or automatically through the use of the controller 450 orother system.

FIG. 23 further illustrates in block 510 that the material handlingsystems 30 pick a first upper chord portion 224 a and a first lowerchord portion 226 a and deliver it to the rigging table system 10 andthen retract to pick additional members. The material handling systems30 place the chord portions 224 a, 226 a within the chord projections 14in order to hold the first chord portions 224 a, 226 a in place.

Block 512 of FIG. 23 illustrates that the material handling systems 30pick one or more sets of webs 238 (e.g., vertical, diagonal, or thelike) from the material supply station 40 and deliver the one or moresets of webs 238 to the rigging table 10. For example, the materialhandling systems 30 may hold the webs 238 in the desired position on thefirst upper and lower chord portions 224 a, 226 a for welding.

FIG. 23 illustrates in block 514 that the one or more welding systems 60weld the one or more sets of webs 238 (e.g., vertical, diagonal, or thelike) to the first upper and lower chord portions 224 a, 226 a. In someembodiments, the welding starts as the material handling systems 30 holdthe webs 238, which are then retracted as the welding is completed.

Block 516 of FIG. 23 further illustrates that the material handlingsystems 30 pick a second upper chord portion 224 b and a second lowerchord portion 226 b from the material supply station 40 and deliversthem to the rigging table 10, such as over the webs 238 and/or spacersof the first upper and lower chords 224 a, 226 a.

FIG. 23 further illustrates in block 518 that in some embodiments theone or more welding systems 60 weld (e.g., tact weld or completely weld)the first upper chord portion 224 b and the second lower chord portion226 b to the webs 238 and/or spacers of the first upper and lower chordportions 224 a, 226 a.

Block 520 further illustrates in FIG. 23 that the joist 220 isdischarged from the rigging table and moved downstream of the riggingtable system 10. For example, the rollers of the rigging table system 10may be engaged (e.g., raised, or the like), which lifts the joist 220out of the projections on the rigging table system 10. The rollers maythen be activated to roll the joist 220 downstream off of the riggingtable system 10. However, it should be understood that systems inaddition to, or other than, rollers 52 may be used to discharge thejoists 220 from the rigging table system 10 (e.g., arm that lifts,overhead track, or the like). In some embodiments users locateddownstream of the rigging table system 10 may complete the welds betweenthe second upper and lower chord portions 224 b, 226 b and the webs 238and/or the spacers of the first upper and lower chord portions 224 a,226 a. In some embodiments, some locations of the joists 220 may bedifficult to access using the welding systems 60, as such, some handwelding may be performed.

FIG. 23 further illustrates in block 522 that notifications may beprovided to users downstream on the user computer systems 420. Thenotifications may be alerts related to the assembly of the joist 220,such as potential welds that need to be checked and/or corrected. Othernotifications may include locations where apertures may need to beformed into the joists 220 (alternatively, the apertures may bepre-formed in the chords 222 and/or webs 238 before being assembled),additional components that need to be added to joists 220 (e.g., bracingclips), joist seats that need to be added to the joists 220, or thelike.

The joist assembly system 1 described herein provides improvements toconventional rigging tables that require users to physically pick up themembers, lift them over their heads, turn around, and/or otherwiseperform a physical operation that could cause harm to the workers, otherworkers, or otherwise interrupt the process of assembling joists on therigging table. The joist assembly system 1 described herein may be ableto assemble joists 220 more efficiently, with less variation, at anincreased rate, or the like when compared to conventional riggingtables.

As will be appreciated by one of skill in the art in view of thisdisclosure, embodiments of the invention may be embodied as anapparatus, a system, computer program product, and/or other device, amethod, or a combination of the foregoing. Accordingly, embodiments ofthe invention may take the form of an entirely hardware embodiment, anentirely software embodiment (including firmware, resident software,micro-code, etc.), or an embodiment combining software and hardwareaspects that may generally be referred to herein as a system.Furthermore, embodiments of the invention may take the form of acomputer program product comprising a computer-usable storage mediumhaving computer-usable program code/computer-readable instructionsembodied in the medium (e.g., a non-transitory medium, or the like).

Any suitable computer-usable or computer-readable medium may beutilized. The computer usable or computer readable medium may be, forexample but not limited to, an electronic, magnetic, optical,electromagnetic, infrared, or semiconductor system, apparatus, ordevice. More specific examples (a non-exhaustive list) of thecomputer-readable medium would include the following: an electricalconnection having one or more wires; a tangible medium such as aportable computer diskette, a hard disk, a random access memory (RAM), aread-only memory (ROM), an erasable programmable read-only memory (EPROMor Flash memory), a compact disc read-only memory (CD-ROM), or othertangible optical or magnetic storage device.

Computer program code/computer-readable instructions for carrying outoperations of embodiments of the invention may be written in an objectoriented, scripted or unscripted programming language such as Java,Pearl, Python, Smalltalk, C++ or the like. However, the computer programcode/computer-readable instructions for carrying out operations of theinvention may also be written in conventional procedural programminglanguages, such as the “C” programming language or similar programminglanguages.

As described herein, when discussing the movement of the members,components and the like as being vertical, horizontal, etc., it isunderstood that the movements in the vertical direction or horizontaldirection may not be exactly vertical or horizontal, such that the termsubstantially or generally vertical or horizontal includes movementsand/or components that are exactly vertical or horizontal, or out of theexact vertical or horizontal plane.

It should be understood that “operatively coupled,” when used herein,means that the components, devices, members, or the like may be formedintegrally with each other, or may be formed separately and coupledtogether. Furthermore, “operatively coupled” means that the componentsmay be formed directly to each other, or to each other with one or morecomponents located between the components that are operatively coupledtogether. Furthermore, “operatively coupled” may mean that thecomponents are detachable from each other, or that they are permanentlycoupled together

Specific embodiments of the invention are described herein. Manymodifications and other embodiments of the invention set forth hereinwill come to mind to one skilled in the art to which the inventionpertains, having the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. Therefore, it is to beunderstood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments andcombinations of embodiments are intended to be included within the scopeof the appended claims. Although specific terms are employed herein,they are used in a generic and descriptive sense only and not forpurposes of limitation.

What is claimed is:
 1. A joist assembly system, comprising: a pluralityof material handling systems; a plurality of welding systems; and arigging table system; wherein the material handling systems load chordsand webs to the rigging table, the rigging table supports the chords andthe webs, and the plurality of welding systems weld the webs to thechords.
 2. The joist assembly system of claim 1, wherein the joistassembly system further comprises: a support structure having a firstlevel and a second level located at least partially above the firstlevel; wherein the plurality of welding systems are located on the firstlevel; and wherein the plurality of material handling systems arelocated on the second level.
 3. The joist assembly system of claim 1,wherein the joist assembly system further comprises: a support structurehaving a first level and a second level located at least partially abovethe first level; wherein the plurality of material handling systems arelocated on the first level; and wherein the plurality of welding systemsare located on the second level.
 4. The joist assembly system of claim1, wherein the plurality of material handling systems are configured topick the chords or the webs.
 5. The joist assembly of claim 1, whereinthe plurality of material handling systems comprise: a plurality ofchord material handling systems; and a plurality of web materialhandling systems.
 6. The joist assembly of claim 1, wherein theplurality of welding systems comprise: a plurality of first weldingsystems adjacent a first side of the rigging table system; and aplurality of second welding systems adjacent a second side of therigging table system.
 7. The joist assembly system of claim 1, whereinthe rigging table system comprises: a plurality of upper chordprojections spaced apart to form a plurality of upper chord cavities,wherein the plurality of upper chord cavities hold a first upper chordportion of an upper chord; and a plurality of lower chord projectionsspaced apart to from a plurality of lower chord cavities, wherein theplurality of lower chord cavities hold a first lower chord portion of alower chord; wherein the plurality of upper chord projections or theplurality of lower chord projections allow the first upper chord portionto be spaced different distances from the first lower chord portion. 8.The joist assembly system of claim 1, the plurality of material handlingsystems hold the webs in place while the plurality of welding systems atleast partially weld the webs to the chords.
 9. The joist assemblysystem of claim 1, wherein the rigging table system comprises web jigsconfigured to hold the webs in place.
 10. The joist assembly system ofclaim 1, wherein the rigging table system is configured to support afirst upper chord portion and a first lower chord portion, and websbetween the first upper chord portion and the first lower chord portion;and wherein the rigging table is configured to support a second upperchord portion over the first upper chord portion and a second lowerchord portion over the first lower chord portion.
 11. The joist assemblysystem of claim 1, further comprising: a material supply station,wherein the material supply station provides the chord portions and thewebs to a picking location for the plurality of material handlingsystems.
 12. The joist assembly system of claim 1, wherein the riggingtable system comprises: a discharging system configured to remove anassembled joist from the rigging table.
 13. The joist assembly system ofclaim 12, wherein the discharging system comprises: a plurality ofrollers, wherein the plurality of rollers are configured to extend fromthe rigging table system and retract within the rigging table system,wherein the plurality of rollers rotate, and wherein when the pluralityof rollers are extended a joist is disengaged from the rigging tablesystem and the plurality of rollers rotate to move the joist off of therigging table system.
 14. A method of assembling a joist using a joistassembly system, wherein the method comprises: retrieving, via one ormore of a plurality of material handling systems, a first upper chordportion of a plurality of upper chord portions and a first lower chordof a plurality of lower chord portions from one or more material supplystations; positioning, via the one or more of the plurality of materialhandling systems, the first upper chord portion and the first lowerchord portion at a rigging table system; retrieving, via the one or moreof the plurality of material handling systems, a plurality of first websof a plurality of webs from the one or more material supply stations;positioning, via the one or more of the plurality material handlingsystems, the plurality of first webs at the rigging table system;joining, via a plurality of welding systems, the first upper chordportion, the first lower chord portion, and the plurality of first webmembers; retrieving, via the one or more of the plurality of materialhandling systems, a second upper chord portion of the plurality of upperchord portions and a second lower chord portion of the plurality oflower chord portions from the one or more material supply stations;positioning, via the one or more of the plurality of material handlingsystems, the second upper chord portion and the second lower chordportion at the rigging table system; joining, via the plurality ofwelding systems, the second upper chord portion and the second lowerchord portion to the plurality of first webs, to the first upper chordportion, or to the first lower chord portion to form a joist; anddischarging, via a discharging system, the joist from the rigging tablesystem.
 15. The method of claim 14, further comprising: providing, viaone or more supply systems, the plurality of upper chord portions, theplurality of lower chord portions and the plurality of webs to the oneor more material supply stations.
 16. The method of claim 14, whereinthe joist assembly system comprises: a support structure having a firstlevel and a second level located at least partially above the firstlevel; wherein the plurality of welding systems are located on the firstlevel; and wherein the plurality of material handling systems arelocated on the second level.
 17. The method of claim 14, wherein theplurality of material handling systems comprise: a plurality of chordmaterial handling systems; and a plurality of web material handlingsystems.
 18. The method of claim 14, wherein the plurality of weldingsystems comprise: a plurality of first welding systems adjacent a firstside of the rigging table system; and a plurality of second weldingsystems adjacent a second side of the rigging table system.
 19. Themethod of claim 14, wherein the one or more of the plurality of materialhandling systems are structured to hold the plurality of first webs inplace while the plurality of welding systems at least partially weld theplurality of first webs.
 20. A computer program product for assemblingjoists, the computer program product comprising at least onenon-transitory computer-readable medium having computer-readable programcode portions embodied therein, the computer-readable program codeportions comprising: an executable portion configured to retrieve, viaone or more of a plurality of material handling systems, a first upperchord portion of a plurality of upper chord portions and a first lowerchord portion of a plurality of lower chord portions from one or morematerial supply stations; an executable portion configured to position,via the one or more of the plurality of material handling systems, thefirst upper chord portion and the first lower chord portion at a riggingtable system; an executable portion configured to retrieve, via the oneor more of the plurality of material handling systems, a plurality offirst webs of a plurality of webs from the one or more material supplystations; an executable portion configured to position, via the one ormore of the plurality material handling systems, the plurality of firstwebs at the rigging table system; an executable portion configured tojoin, via a plurality of welding systems, the plurality of first webs tothe first upper chord portion and the first lower chord portion; anexecutable portion configured to retrieve, via the one or more of theplurality of material handling systems, a second upper chord portion ofthe plurality of upper chord portions and a second lower chord portionof the plurality of lower chord portions from the one or more materialsupply stations; an executable portion configured to position, via theone or more of the plurality of material handling systems, the secondupper chord portion and the second lower chord portion at the riggingtable system; an executable portion configured to join, via theplurality of welding systems, the second upper chord portion and thesecond lower chord portion to the plurality of first webs, to the firstupper chord portion, or to the first lower chord portion to form ajoist; and an executable portion configured to discharge, via adischarging system, the joist from the rigging table system.